SUMMARY
The Controls Engineer III is responsible for developing innovative automation solutions for packaging machinery. This role provides leadership to a cross-functional team of mechanical and controls engineers, assembly technicians, and validation staff in a matrix organization, with an emphasis on new product development and engineering for commercial products. Working closely with the Electrical Engineering Manager, this individual specifies new equipment in alignment with market needs.
This job description highlights the primary responsibilities and authority of the position but is not intended to be all-inclusive.
ESSENTIAL FUNCTIONS
New Machinery Development
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Create new machinery concepts, including automation specifications, configuration options, and cost targets for prototype systems.
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Estimate time and material requirements for new machinery quotes.
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Direct concept development using test rigs and components.
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Present specifications for milestone reviews and maintain updated documentation.
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Report project deviations, risks, and cost variances to the Electrical Engineering Manager.
Engineering of New Equipment and Machinery Lines
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Develop automation platforms, control architectures, electrical assemblies, schematics, and bills of material (BOMs).
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Design control cabinet layouts, conduit systems, and program HMI, PLC, and robotic control software.
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Document BOMs and ensure accuracy for product configuration.
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Manage and record all Engineering Change Requests (ECRs) and Engineering Change Notices (ECNs).
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Lead technical design reviews to ensure peer review and knowledge sharing.
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Ensure compliance with all applicable safety standards (OSHA, EU Machinery Directive, and local authorities) and integrate safety risk assessments.
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Provide project management and technical leadership from order entry through field testing.
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Serve as the technical liaison with customers, sales, and project management, communicating specifications, project plans, and change orders.
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Direct assembly and validation staff during build and test phases.
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Partner with sales, project management, and service teams to resolve technical field issues.
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Upon field test completion, transfer prototype documentation to the commercial engineering team.
Process Improvement and Knowledge Sharing
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Mentor colleagues in machinery development practices and serve as a subject matter expert (SME) in key competency areas.
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Support refinement of the product development process to improve lead times, cost efficiency, quality, and safety.
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Stay current on automation technologies and share insights with the engineering team.
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Report machine performance and safety concerns to the Electrical Engineering Manager.
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Perform other duties as assigned.
EDUCATION AND EXPERIENCE
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Bachelor’s degree in Electrical Engineering, or associate degree in Engineering with 7+ years of relevant experience designing and programming PLC, HMI, and servo control systems.
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Experience with high-speed servo-driven machinery required.
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Familiarity with Allen-Bradley (AB) and Fanuc PLC systems.
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Proficiency with Rockwell Automation software and hardware (RSLogix5000, ControlLogix, CompactLogix, PowerFlex VFDs, Kinetix servo drives, PanelView HMIs) preferred.
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5+ years of AutoCAD experience in schematic generation required.
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Experience with 3D parametric CAD and Product Data Management (PDM) systems preferred.
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Prior exposure to packaging or cam-driven machinery preferred.
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Experience specifying robotics and pick-and-place systems preferred.
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Project management and customer-facing experience strongly preferred.
TECHNICAL SKILLS AND ABILITIES
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Capable of designing and managing control systems for machinery and integrated packaging lines.
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Strong ability to read, analyze, and troubleshoot electrical schematics and engineering software.
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Proficiency in Microsoft Office tools.
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Skilled in mentoring and leading design and project teams.
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Strong problem-solving, troubleshooting, and critical thinking abilities.
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Ability to adapt to a fast-paced, dynamic environment.
INTERPERSONAL COMMUNICATION
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Communicates effectively, both verbally and in writing, with individuals and groups at all levels, internal and external.
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Works collaboratively with cross-functional teams and demonstrates flexibility in partnering with diverse personalities.
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Contributes to team problem-solving by suggesting ideas and resolving issues constructively.
